MAINTAINING ASSET INTEGRITY IN THE

OIL AND GAS INDUSTRY UPSTREAM

Belzona Protective Coatings and Repair Composites

Maintaining Asset Integrity in the Oil and Gas Industry Upstream

OUR HISTORY
Established in 1952, Belzona has pioneered innovative polymer technology that has revolutionised industrial
repair and maintenance procedures. Proven success has also led to a growing number of prominent clients
specifying Belzona materials as a cost effective solution at the design stage of a project.
Today, Belzona is the world leader in the supply of polymer repair composites and industrial protective
coatings and is continuously developing solutions to meet the ever increasing market demand.

100% solids epoxy protective linings for

erosion-corrosion protection

High performance polyurethanes for

flexible repairs

Composites for bonding, forming,

shimming and rebuilding

NOVEL SOLUTIONS TO AGE-OLD PROBLEMS

Aggressive chemicals and erosion-corrosion can take their toll on equipment and structures, resulting in
increased capital and operating expenditure. Elevated temperature and pressure levels tend to exacerbate
the problem and necessitate the use of high performance protective and repair materials with a proven
track record. By utilising a Belzona solution, asset owners and engineering houses can incorporate suitable
protection into the design of a newly built piece of equipment. Components that have been damaged in
service can also be refurbished. Oil and Gas companies choose the Belzona solution because it helps them to:

Reduce capital expenditure

Lower maintenance costs
Improve efficiency and safety
Reduce downtime
Simplify maintenance procedures
Extend machinery and equipment life

Belzona offers a range of coatings and composites carefully formulated to address various issues faced by
the Oil and Gas industry. We take pride in the quality of our materials as well as the comprehensive training
and field support we provide to ensure the highest possible application standards.

Company established,
offering zinc-rich
anticorrosive coatings

1950

BELZONA
TIMELINE

First corrosion
resistant steel
alloy applied

1960
First cold curing
Metallic Polymers
introduced

Began servicing
the Oil and Gas
industry

1970
Ceramic metals
introduced

1980
Elastomers for
flexible repairs
formulated

Belzona Protective Coatings and Repair Composites

GLOBAL PRESENCE - LOCAL SUPPORT

Belzona have over 140 Distributors in more than 120 countries ensuring not only the availability of Belzona
materials, but also specification support, project management, application and supervision services.
Distributorships and their teams are supported by Belzona Corporate offices in Europe, North America and
Asia.
To find your local Belzona
representative visit
belzona.com/find

CORPORATE OFFICES
Belzona Canada
Ontario, Canada
t: +1 (905) 737-1515
f: +1 (905) 737-1597
Belzona Inc
Miami, Fl, USA
t: +1 (305) 594-4994
f: +1 (305) 599-1140
Belzona Polymerics Ltd
Harrogate, UK
t: +44 1423 567641
f: +44 1423 505967
Belzona Asia Pacific
Chonburi, Thailand
t: +66 38 491031
f: +66 38 491102

Our expert Technical Consultants with years of field experience and advanced training are available to
assist you every step of the way to: discuss material selection options, diagnose the problem, recommend a
solution and provide on-site application support.

Erosion-corrosion
resistant linings for
high temperature
immersion launched

1990

Next generation
vessel linings
formulated

Heat activated corrosion

under insulation repair
products introduced

2000

Introduced
compliant pipe
wrap technology

2010
Sprayable erosion
resistant linings
developed

New peelable
coating concept
introduced

Maintaining Asset Integrity in the Oil and Gas Industry Upstream

INTERNAL SURFACE PROTECTION FROM

FLOWING CORROSIVE MEDIA
Process vessels - protection, reclamation and modification
Applied at ambient temperatures,
VOC-free Belzona linings facilitate
corrosion prevention, repairs and vessel
modifications.
Belzona liquid applied vessel linings
were first specified in 1987 for separator
corrosion repair and protection at a UK
North Sea platform. Outstanding erosion
resistance prevented wear during the
sand jetting system operation and has
prompted the use of Belzona linings on
hundreds of other vessels. We now offer
a complete solution for pressure vessels
handling liquid hydrocarbons, gas and
process chemicals including separators,
slug catchers, knock-out drums and
many more. Based on the experience of
corrosion repair and prevention, spanning
two decades, in the early 2000s asset
owners and operators began to specify
Belzona linings at the design stage to
protect newbuild vessels.
Our linings can be spray or hand applied
and, once cured in service, form a barrier
between the substrate and corrosive
media, enabling the operator to implement
a corrosion management plan. As well as
resisting erosion-corrosion, Belzona linings
are designed to withstand vast pressure
and temperature fluctuations, including
steam-out and explosive decompression.
In addition to internal vessel lining, a
complete corrosion solution includes small
bore nozzle and flange face protection in
order to fully isolate the substrate from a
corrosive environment. Belzona vessel lining
systems offer long-term corrosion protection
and are easier to maintain than alternative
corrosion protection technologies.

Belzona lining applied to a newly fabricated separator

Cold forming isolates flange faces

from corrosive media

Prefabricated Belzona inserts bonded

into small bore nozzles

Belzona Protective Coatings and Repair Composites

Video: Process vessel

corrosion protection

VESSEL LINING REPAIRS

Failed coatings (or Belzona linings
due for planned maintenance) can be
repaired in situ with minimal disruption
to operations. Patch repair, partial
recoat or full recoat options reduce
downtime, prolong vessel service life
and extend maintenance-free periods.

FLANGE FACE FORMING

Touch up after 9 years

Glass flake lining repair

Full recoat

Corroded flange

Forming technique

Completed application

Deteriorated nozzle

Pre-fabricated insert

Nozzle protected

Separator modification

Cold bonding technology

8 years later

Crevice and galvanic corrosion can be

prevented or repaired with a unique
Belzona composite forming technology.
Prefabricated formers are used to
shape the specified Belzona material
that bonds strongly to the flange face.
The sealing face is then effectively
isolated from corrosive media whilst
maintaining its shape and profile.

SMALL BORE NOZZLE

PROTECTION
Narrow nozzles no longer need to
be considered the Achilles heel of
process vessels. Tailor made Belzona
inserts can be bonded into the nozzle
using a fluid grade material, eliminating
the risk of pinholes or holidays.
Excellent chemical and erosion
resistance ensures long-term protection
of the nozzle, thus extending
maintenance-free periods.

VESSEL MODIFICATION
Where hot work is not permissible
or desirable, cold bonding of vessel
internals allows for modification and
eliminates the need for post weld heat
treatment. Tensile shear, tensile and
cleavage adhesion tests performed
show that Belzona bonding can be
superior to welding.
For more information read In Focus:
Process Vessels, belzona.com/vessels

Maintaining Asset Integrity in the Oil and Gas Industry Upstream

INTERNAL SURFACE PROTECTION FROM

FLOWING CORROSIVE MEDIA
Transfer pipe erosion-corrosion protection lining
Sand entrainment and high flow rates
coupled with large quantities of CO2, H2S
and brine can lead to pipe corrosion rates
of several hundred mils per year. In 2012,
Belzona pioneered a spray-friendly pipe
lining system that offers erosion-corrosion
protection. The substitution of hardceramic fillers for a thermoplastic filler
blend ensures there is very little wear to
the spray equipment.
Sprayable erosion-corrosion protective
linings allow for the material to be spin
spray applied in situ at wet film thickness
up to 2000 microns without sagging,
effectively covering girth welds and joints
in a single coat. The thermoplastic filler
blend is formulated to achieve excellent
impact and sliding abrasion resistance, a
high degree of toughness and chemical
resistance.

Internal pipe lining

Next generation pipe linings are available

in medium and elevated temperature
variations of up to 95C (203F).
When comparing Belzona sprayable
thermoplastic filler blend linings with
ceramic filled epoxies, abrasion tests
revealed reduced volume loss. Tests and
in-service performance confirm that these
novel linings provide outstanding erosion
resistance in extreme wear environments.
For more information download a white
paper on belzona.com/1331

Girth weld covered in a single coat

Spin spray application

Video: Spin-sprayed
pipe lining

Belzona Protective Coatings and Repair Composites

Video: Pump repair

and protection

PUMPS
Pump deterioration leads to decreased
pumping efficiency and eventually costly
part replacement. Pitting, worn wear
ring clearances as well as casing thin and
through wall defects can be rebuilt using
composites specifically designed for
pumping applications. Pumping efficiency
is restored and enhanced with the use
of a hydrophobic smooth lining, which
also protects from erosion-corrosion
and cavitation. Once the pump has been
protected with Belzona, it can remain
maintenance-free for many years.

New firewater pump lining

Impeller protected with Belzona lining

Seawater lift pump chambers

Protected with Belzona lining

Due to over 30 years experience in

repairing and restoring upstream pumps,
Belzona linings are now specified to
protect new pumps, thus significantly
extending the lifetime of the assets and
subsequent maintenance-free periods.
Belzona linings have become a first choice
in protecting firewater pumps in particular,
offering long-term corrosion protection
and seizure prevention.
For more information on Belzona solutions
for pumps view a 3D map detailing various
application areas and case studies on
belzona.com/pumpmap

Maintaining Asset Integrity in the Oil and Gas Industry Upstream

STRUCTURAL BONDING
Applied at ambient temperatures, 100% solids Belzona materials create a high
performance adhesive.
Design and maintenance scenarios that
would historically involve hot work can
be completed with the use of polymeric
cold bonding composites. This technology
is applied and cures at ambient
temperatures, thus improving safety and
reducing downtime.
Belzona bonding was first used in the late
1950s to attach equipment ID tags. Over
the years materials were enhanced to
resist higher pressures and temperatures
as well as demonstrate comparably high
adhesion and compressive strength.

COLD WELDING DECK

EQUIPMENT
Cold bonding deck equipment eliminates
the need for hot work and facilitates rapid
installation. With tensile shear adhesion
of up to 2,960 psi (20.4MPa), pull off
adhesion of up to 3,240 psi (22.3MPa)
and flexural strength of up to 14,300 psi
(98.6MPa) deck equipment, framework
and supports can be bonded permanently
and safely. Belzona cold bonding is equally
effective at a fabrication stage, during
turnarounds or whilst the platform is in
operation. Belzona cold bonding materials
are also recommended to fill gaps arising
in tack welded elements, such as pipe
saddles supports.

Cable tray bonded on FPSO

DECK MAINTENANCE
- PLATE BONDING
Corroded equipment and structures
can be repaired in situ with Belzonas
pioneering injection bonding technology.
This technique has been successfully
utilised for deck renovation and other
structural integrity repairs. Over a decade
of successful applications, which are still
in service today, attest to this methods
effectiveness and have prompted
engineering houses to specify injection
bonding for greenfield applications.

Corroded deck on Buchan Platform

Belzona plate bonding

To see Belzona Know-How in action,

including bonding applications, visit
khia.belzona.com - our dedicated case
study database

Video: Injection
bonding

8 years later, Belzona plate bonding solution in excellent condition

Belzona Protective Coatings and Repair Composites

BEARING INSTALLATION/
BONDING
Bearings are susceptible to friction
damage and galvanic corrosion. Since the
1970s, Belzona has been used to prevent
bearing corrosion by seating rudder pintle
bearings.
After a trial ship application in 1979,
Belzona was accepted as a permanent
installation and used from new on all
Germanisher Lloyd classed vessels.
One of the first and perhaps most notable
bearing bonding applications in service
today was performed on a flagship liner,
Queen Elizabeth 2.

Rudder bearing bonding top view

Rudder bearing bonding bottom view

Bush installation, North Sea

Riser bearing bonding

Bearing bonding is carried out by injecting

the Belzona material between the bearing
and the housing. The Belzona shim takes
up any ovality or housing wear, thus
creating a durable barrier with 100%
surface contact, electrically isolating the
bearing. This method has been applied to
multiple situations including riser bearings
and bushes amongst others.

Maintaining Asset Integrity in the Oil and Gas Industry Upstream

PIPEWORK EXTERNAL CORROSION

REPAIR AND PROTECTION
Heat activated solutions applied on-line
CUI REPAIRS
Corrosion under insulation occurs at
an accelerated rate and can remain
undetected for some time. Taking affected
parts of the pipework out of service for
repairs or replacement can in turn lead
to high costs and lengthy downtime. To
address this problem, in the late 1990s,
Belzona formulated heat activated
composites and coatings that facilitate
on-line repairs. These materials adhere
exceptionally well to hot contaminated
surfaces and penetrate deep into the
substrate eliminating the need for an
angular blast profile prior to application.
Simple manual surface preparation and
on-line brush application have inspired the
use of Belzona heat activated materials
to combat CUI globally, from the Gulf
of Mexico to the North Sea. Typical
applications in the range of -10C to 150C
(50F 302F) will resist salt spray and
commonly found inorganic acids and
alkalis at concentrations up to 20%.

Corrosion under insulation

Insulation can then be sealed with a

breathable membrane to prevent further
liquid permeation. Belzona membrane can
be easily cut open for localised inspection
and resealed with little impact on the
process.
For more information on CUI solutions
visit belzona.com/cui

Video: Heat activated

application

Pit filling

Coating application

Belzona Protective Coatings and Repair Composites

PIPEWORK EXTERNAL CORROSION

REPAIR AND PROTECTION
Cold applied 100% solids materials
PIPE WRAPS AND PLATE
BONDING
Thin and through wall defects caused
by external and internal corrosion can
be repaired using composite wrap
systems. A wrap system is composed
of a reinforcement sheet and a Belzona
material, tailored to the assets performance
criteria, such as presence of contaminants,
operating temperatures and pressures
amongst others. A wrap system can also be
applied in conjunction with a bonded plate
where additional reinforcement is required.

Holed pipe

Belzona SuperWrap applied

Following almost five decades of pipe

wrap installations, in 2007 we added
Belzona SuperWrap to the range, which
is compliant with ASME PCCC2 Article
4.1 and ISO/TS 24817 and withstands
pressures exceeding 250 bar. Every
Belzona SuperWrap system is individually
designed and is applied by validated
installers, carrying a warranty based on
the estimated design life. In 2014, three
next generation variations of Belzona
SuperWrap were released to better
accommodate different climates and
environments winter, tropical and high
temperature grades.

T-piece wrap

T-piece wrap

Simple brush application

Completed application

For more information read In Focus: Pipe

Wraps on belzona.com/wraps

FLANGE PROTECTION
Repairing flange crevice corrosion
can be a very costly exercise, whereas
common preventative measures in most
cases are not inspection friendly. The
Belzona encapsulating membrane system
introduced in 2014 seals bolted flange
connections preventing corrosion. The
liquid applied system includes a corrosion
inhibitor and was designed to allow
for periodic inspection, where flexible
protection can be cut, peeled back and
then easily resealed. To maintain Health
and Safety standards, the system is hand
applied, cures at ambient temperatures
and can resist common corrosive media.
For more information visit belzona.com/3411

Video: Application,
peeling and resealing

Peel to inspect, reseal to protect

Maintaining Asset Integrity in the Oil and Gas Industry Upstream

MARINE WORK
Splash zones applications above and below the water line
Constant salt spray and wave impact
create perfect conditions for vast erosioncorrosion and necessitate in-situ repairs
in order to avoid replacement costs. To
address these issues, Belzona formulated
a surface-tolerant coating and composite
in 2002. Applied and cured above or
below the water line, these materials have
the ability to displace contaminants and
bond strongly to the substrate. These
surface-tolerant materials are specified
where contact with water and other
contaminants is present during their
application on risers, platform legs and
other splash zones.

Corroded riser

Corrosion repaired and cladding sealed

Corroded platform leg

Coating applied

RISERS
Rubber cladding does not offer permanent
protection and tends to deteriorate
after a few years in service, with sea
water corroding the steel underneath
the cladding. Belzona offers a complete
system, which restores corroded metal
and repairs cladding in situ, sealing the
neoprene boot topping of the riser, thus
preventing further water permeation.
Due to proven longevity of cladding edge
sealing, marine engineers specify Belzona
flexible solution on new risers to prevent
water ingress between the cladding and
the metal.

PLATFORM LEGS
Sea water movement with abrasive
residues is capable of wearing away
sacrificial protection and causing severe
damage to the platform legs, particularly
around the water line. Belzona surfacetolerant materials can be used to rapidly
repair and prevent platform leg corrosion.
Liquid-applied in situ and long lasting, the
system forms a durable barrier between
the substrate and the sea water.

SUBSEA COATINGS
Following over a decade of applications
on platform legs, FPSO operators specify
Belzona surface-tolerant materials for hull
coating repairs and other subsea coating
applications.
For more information on Belzona solutions for
splash zones visit belzona.com/splashzones

Video: Riser repair

Inspected five years later

Belzona Protective Coatings and Repair Composites

MARINE WORK
Flexible repairs liquid applied durable protection
Auxiliary rubber equipment such as
fenders, hoses and cables are prone to
in-service deterioration, where even minor
rips and tears can lead to equipment being
decommissioned. Belzona Elastomers
are liquid-applied flexible polyurethanes,
which can reduce downtime and eliminate
the need for replacement. First introduced
in 1985, Belzona Elastomers are commonly
used in situations where replacement is
too costly and alternative materials are not
able to provide a durable repair.

FLOATING HOSES AND

FENDERS

Hose damaged in transport

Belzona flexible repair

Deteriorated fender

Fender repaired in situ

Hoses can be damaged in service or in

transit and require a fast and durable
repair solution. Belzona Elastomers
adhere strongly to any type of hose
and provide outstanding abrasion and
impact resistance once the hose is put
back in service. Belzona Elastomers are
endorsed by reputable floating hose
manufacturers as their recommended
repair material. Corroded flange faces and
internal surfaces can also be repaired and
protected with the use of Belzona lining
and flange face forming technology.
For more information on floating hose
repairs visit belzona.com/hoses

Video: Floating hose

repair

Maintaining Asset Integrity in the Oil and Gas Industry Upstream

GLOBAL APPLICATION STANDARDS

PREQUALIFICATION
Belzona materials are subject to stringent independent and
in-house testing, documented in the product specification
sheets and chemical resistance charts. Testing is performed
in our ISO 9001 audited laboratory to recognised standards,
including NACE, ASTM, ISO, Lloyds and many more. Numerous
high profile Oil and Gas companies prequalify the use
of Belzona materials at the design stage and for asset
maintenance.
Data collected from the field influences improved formulations
and application methodology to ensure increasingly efficient
in-service performance.

SPECIFICATION
Optimum materials and application procedures are selected
to meet specific design and operating conditions of the asset.
Dedicated project engineers coupled with round the clock
head office technical support allow for the correct material
and application procedure to be specified.
We also maintain a comprehensive database accessible by the
Global Belzona Distributor network, which facilitates sharing
of information and experience, improving specification and
application standards.

APPLICATION
Application standards, including surface preparation, are
integral to the success of solution implementation. Belzona
recognises the need to set and monitor global application
standards.
Applications are carried out by experienced and trained
personnel. Belzona runs training programmes with theoretical
and practical courses, including validated training. Combined
with method statements, quality control procedures and daily
inspection reports we strive to ensure application standards
are maintained.

INSPECTION
Inspection is carried out by certified inspectors (e.g.
NACE, FROSIO) prior to, during and upon completion of
the application to ensure Belzona systems are applied in
accordance with our standards and clients requirements.
Upon nearing the end of the systems expected service
life, the asset is inspected again and appropriate action
recommended, which may involve minor repair work or no
action, as Belzona systems tend to outlast projected service
life.

Belzona Protective Coatings and Repair Composites

BELZONA SOLUTIONS FOR THE

OIL AND GAS INDUSTRY UPSTREAM
HIGH PERFORMANCE LININGS

COLD BONDING

WRAPS

HEAT ACTIVATED COATINGS

SURFACE-TOLERANT PROTECTION

ELASTOMERS

resistant to high pressures and temperatures

for pressurised pipework repairs

for applications above and below the waterline

to replace hot work

for hot surface repairs on-line

for flexible repairs

ISO 9001:2008
Q 09335
ISO 14001:2004
EMS 509612
Belzona products are manufactured
under an ISO 9000 Registered Quality
Management System

Copyright Belzona International Limited 2014

UK USA Canada Thailand

www.belzona.com

ZCORPOGU(E)06/14